Hardshell modular lightweight load-carrying equipment system and method of making thereof

ABSTRACT

The present disclosure relates to an improved Modular Lightweight Load-carrying Equipment (MOLLE) system that employs hard-shells and a method of making thereof. The disclosed hard-shell MOLLE system not only provides better durability for the MOLLE system, but also allows the MOLLE system to apply on hard objects such as thermoformed/molded backpacks, bags, vehicle panels and containers etc.

This application is a continuation of U.S. application Ser. No. 15/877,260, filed on Jan. 22, 2018 the disclosure of which is hereby incorporated by reference.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to Modular Lightweight Load-carrying Equipment (MOLLE) system. More specifically, the present disclosure discloses a method of creating hard-shell MOLLE system that can be applied on anything that employs MOLLE system such as military backpacks, vests and quad vehicles. The present disclosure further discloses an exemplary backpack that employs the disclosed hard-shell MOLLE system.

BACKGROUND OF THE INVENTION

Modular Lightweight Load-carrying Equipment (MOLLE) system refers to the current generation of load-bearing equipment and backpacks used by a number of NATO armed forces including the United States Army. As shown by FIG. 1 , conventional MOLLE systems employ Pouch Attachment Ladder System (PALS) webbing 2 as rows of heavy-duty nylon stitched onto the military backpacks, bags, vests and similar sewn products to allow for the attachment of various compatible pouches and accessories such as various sizes of magazines, knives, water bottle etc. This method of attachment has become a de facto standard for modular tactical gear.

The present disclosure discloses an improved MOLLE system using hard-shells and a method of making thereof, which not only increases the durability of the MOLLE system, but also allows the MOLLE system to be used on hard objects such as thermoformed/molded backpacks, bags, vehicle panels, containers etc.

SUMMARY OF THE INVENTION

One objective of the present disclosure is to provide an improved MOLLE system that allows the MOLLE system to be applied on hard objects and a method of making thereof. Another objective of the present disclosure is to provide an improved MOPLLE system that has a better durability and has the capability to load and carry more accessory and equipment.

In accordance with one embodiment of the present disclosure, a method of employing MOLLE system on a surface of a hard object is disclosed. The method comprises: 1) creating a plurality of depressed channels on a surface of a hard object in parallel to create a plurality of vertical canals, wherein distance between each vertical canal and its adjacent vertical canal is same; 2) placing a plurality of cross members made of a hard material across the plurality of vertical canals in parallel, wherein the plurality of cross members is perpendicular to the plurality of vertical canals, forming a grid; and 3) fixing the plurality of cross members to the surface of the hard object with screws or rivets.

In other words, the present disclosure works by creating depressed channels in the molded material when formed that establish vertical canals for the users' fingers to pass and for the pouch mounting-straps, or other hardware to pass. The second part of the disclosed system is to have cross members to pass over them at 90 degrees forming the traditional grid pattern. The cross members may be rigid such as polymer sheets, molded plastic parts, or webbing. They can be fixed with hardware such as screws/rivets or sewn. If made of plastics, the cross members have the added utility of being able to have perforations making them capable of accepting screws and attaching items like lights, knife sheaths and camera equipment like action cameras. This would not be possible in the traditional webbing because putting holes in the nylon webbing would damage it, and there is no way to access the back since they are on a flat fabric surface without the channels in the back. The molded mounting surface may further comprise molded depressions that guide the placement of the cross-members and prevent their lateral movement. This makes assembly easier for the worker and necessitates only 3rd dimension staking at the rivet/sewing points.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram showing traditional MOLLE systems with PALS webbing.

FIG. 2 is a schematic diagram according to an exemplary embodiment of the present invention.

FIG. 3 is a schematic diagram according to an exemplary embodiment of the present invention.

FIG. 4 is a schematic diagram according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) AND INVENTION

The following description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the disclosure, since the scope of the disclosure is best defined by the following claims. Various inventive features are described below that can each be used independently of one another or in combination with other features.

Broadly, embodiments of the present disclosure generally relate to a hard-shell Modular Lightweight Load-carrying Equipment (MOLLE) system and a method of making thereof. In one embodiment, as shown by FIG. 2 , a method of employing MOLLE system on a surface of a hard object is disclosed, the method comprises: creating a plurality of depressed channels on a surface of a hard object 4 such as a thermoformed or molded backpack in parallel to create a plurality of vertical canals 6, wherein distance between each vertical canal 6 and its adjacent vertical canal 6 is the same; placing a plurality of cross members 8, preferably made of a hard material, across the plurality of vertical canals 6 in parallel, wherein the plurality of cross members 8 is perpendicular to (e.g., 90 degrees) the plurality of vertical canals 6, forming a grid; and fixing the plurality of cross members 8 to the surface of the hard object 4. Note that the disclosed method can be applied on surface of any hard object such as a hard-shell bag, a quad vehicle panel or a container and is not limited to thermoformed or molded backpack. The hard object may include, but is not limited to, things made of plastic, metal, fiberglass, wood, glass or combination thereof. The cross members 8 may be rigid such as polymer sheets, molded plastic parts, metal or webbing, where they can be fixed to the hard object with hardware such as screws/rivets 12 or sewn. Preferably, dimensions of the vertical canals 6, especially the width and depth, are configured in a way to allow a user's fingers to pass and for the pouch mounting-straps, or other common MOLLE hardware to pass.

In one embodiment, as shown by FIG. 2 , the disclosed method further comprises creating a plurality of molded depressions 10 in parallel on the surface of the hard object 4 that are also perpendicular to and cross the plurality of vertical canals 6, wherein each molded depression 10 is configured to fit one crossing member 8. One advantage of making the molded depressions 10 is that they can serve as guides for the crossing member's 8 placement during assembly which makes assembly easier for the worker and necessitates only 3rd dimension staking at the rivet/sewing points. The molded depressions 10 also prevent lateral movement of the crossing members 8. The depth of the plurality of molded depressions 10 should be less than depth of the plurality of vertical canals 6 so a space is created between the vertical canals 6 and the cross members 8. Preferably, the shape of the plurality of molded depressions 10 should be designed to resemble the shape of the plurality of cross members 8, which can also increase the aesthetics aspect of the disclosed MOLLE system as shown by the figure.

In yet another embodiment of the present disclosure, the disclosed method further comprises perforating a plurality of holes 14 on the plurality of cross members 8. This is possible when the cross members 8 are also made of a hard material such as molded plastic, polymer sheet and/or metal. The plurality of holes 14 adds the utility of making the disclosed hard-shell MOLLE system capable of accepting screws and attaching items like lights, knife sheaths and camera equipment like action cameras. For instance, as shown by FIG. 4 , each of the plurality of cross members 8 has holes with 0.25 inch in diameter. The holes can be used as screw holes for attaching various equipment such as camera or the camera mount. The size of holes can be customized by the user depending on the type of equipment the user intended to mount or attach to the cross members 8. This would not be possible in the traditional webbing because putting holes in the nylon webbing would damage it, and there is no way to access the back since they are on a flat fabric surface without the channels in the back.

The number of vertical canals 6 and cross members 8 may vary depending on the design and/or the surface size of the hard object 4, and it not limited to 4 by 4 grid as shown by the figures. For examples, there can be three vertical canals 6 with six cross members 8 (i.e., 3 by 6 grid), or six vertical canals 6 with five cross members 8 (i.e., 6 by 5 grid). While the length (i.e., the longer side) of the vertical canals 6 will vary depending on the design, the width of the vertical canal 6 preferably should be kept within 24 millimeter (mm) to 30 mm to create best performance. Similarly, while the length and thickness of the cross members 8 can vary depending on the design or size of the grid, the width of the cross member 8 should be kept within 21 mm to 30 mm.

In yet another embodiment of the present disclosure, the length for each crossing member 8 and/or molded depression 10 is configured in a way so that it is greater than the width of all vertical canals 6 combined, and length for each of the plurality of vertical canal 6 is also configured to exceed the width of all cross members 8 combined. This provides better performance for the disclosed hard-shell system and also increases its aesthetic appearance.

In yet another embodiment of the present disclosure, as shown by FIG. 3 , a backpack 16 employing the disclosed hard-shell MOLLE system is disclosed comprising a rigid outer shell 18 and at least one flexible shoulder strap 20, preferably two, for securing the rigid outer shell 18 to a user. The rigid outer shell 18 further comprises a plurality of vertical canals 6 aligned in parallel, where distance between each vertical canal 6 and its adjacent vertical canal 6 is same; and a plurality of cross members 8 made of a hard material (e.g., polymer sheets, molded plastic parts, metal etc.) which are placed across the plurality of vertical canals 6 in parallel and is perpendicular to the plurality of vertical canals 6 forming a grid. The plurality of cross members 8 is fixed to the rigid outer shell 18 through an attaching mean such as using screw/rivet, glue, or sewn. The number of vertical canals 6 and cross members 8 can vary depending on the design or the size of the backpack 16. For example, it can be a 4 by 4 grid as shown by the figure. The cross members 8 may further comprise a plurality of holes 14 so they are capable of accepting screws and attaching items like lights, knife sheaths and camera equipment like action cameras.

In one embodiment, the rigid outer shell 18 of the backpack 16 further comprises a plurality of molded depressions 10 aligned in parallel that are perpendicular to and cross the plurality of vertical canals 6 forming a grid, where depth of the plurality of molded depressions 10 is less than depth of the plurality of vertical canals 6. Preferably, the shape of the plurality of molded depressions 10 should be designed to resemble the shape of the plurality of cross members 8, which can also increase the aesthetics aspect of the disclosed MOLLE system as shown by FIG. 3 .

For optimal performance and appearance, it is suggested that the length for each crossing member 8 and/or molded depression 10 is configured to be greater than the width of all vertical canals 6 combined, and length for each of the plurality of vertical canal is also configured to exceed the width of all cross members 8 combined. Further, the width of the vertical canal 6 preferably should be kept within 24 millimeter (mm) to 30 mm and the width of the cross member 8 should be kept within 21 mm to 30 mm. FIG. 4 shows an exemplary dimension in millimeters for a cross member 8 of a 4 by 4 grid (e.g., four vertical canals with four cross members) with holes 14.

In yet another embodiment, the interior of the backpack is different than the outside (i.e., the rigid outer shell). In other word, the interior of the molded section of the molding is different than on the outside so as to form counter-sunk holes for the rivets/screws to live in without scratching the contents of the backpack.

It should also be noted that when the term “a”, “an”, etc. is used, it is to be interpreted as “at least one” throughout the application, drawings, and claims.

Finally, it is the applicant's intent that only claims that include the express language “means for” or “step for” be interpreted under 35 U.S.C. 112, paragraph 6. Claims that do not expressly include the phrase “means for” or “step for” are not to be interpreted under 35 U.S.C. 112, paragraph 6.

While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed. 

1. An apparatus for securing one or more items to a pack adapted for being carried by a user, comprising: an elongated cross member including a plurality of openings, the plurality of openings including at least one intermediate opening; and fasteners for removably securing the cross member to the pack; wherein the cross member comprises an intermediate portion offset from a surface of the pack when the cross member is secured thereto, the intermediate portion including the at least one intermediate opening.
 2. The apparatus of claim 1, wherein the cross member comprises a plurality of intermediate openings.
 3. The apparatus of claim 1, wherein the cross member includes at least two end openings, each for receiving one of the fasteners for removably securing the cross member to the pack.
 4. The apparatus of claim 3, wherein the cross member includes a middle opening for receiving another fastener for securing a middle portion of the cross member to the pack.
 5. A pack including the apparatus of claim
 1. 6. An apparatus adapted for being carried by a user, comprising: a pack including a first side having at least one strap for carrying the pack and a second side opposite the first side including a plurality of cross members removably attached to the pack and not connected to each other; at least one cross member of the plurality of cross members includes a portion spaced from an adjacent surface of the pack so that a connector may be inserted in a space between the at least one cross member and the surface to connect one or more items to the at least one cross member.
 7. The apparatus of claim 6, wherein the at least one cross member includes a plurality of openings for receiving fasteners for fastening to the pack.
 8. The apparatus of claim 6, wherein end portions of the at least one cross member contact a first surface of the pack and an intermediate portion of the at least one cross member is elevated above a second surface of the pack so as to form the space.
 9. The apparatus of claim 6, wherein the second side of the pack is rigid.
 10. The apparatus of claim 6, wherein the second side of the pack includes a plurality of canals recessed from the adjacent surface and forming the space.
 11. The apparatus of claim 10, wherein the plurality of canals extend transverse to the plurality of cross members.
 12. The apparatus of claim 11, comprising four cross members and four canals.
 13. An apparatus adapted for being carried by a user, comprising: a pack including a first side associated with at least one strap for being worn by the user and a second side including at least one cross member having first and second end portions and an intermediate portion between the first and second end portions, the first and second end portions connected to the pack and the intermediate portion offset from an adjacent surface of the pack when the cross member is secured thereto.
 14. The apparatus of claim 13, wherein the intermediate portion includes an intermediate opening.
 15. The apparatus of claim 13, wherein the adjacent surface is in a canal formed in the second side of the pack.
 16. The apparatus of claim 13, further including a plurality of fasteners for connecting the first and second end portions to the pack.
 17. The apparatus of claim 13, wherein the second side of the pack is rigid.
 18. The apparatus of claim 13, wherein the second side of the pack includes a plurality of canals recessed from the adjacent surface and forming the space.
 19. The apparatus of claim 13, wherein the plurality of the canals extend transverse to the plurality of cross members.
 20. The apparatus of claim 13, comprising four cross members and four canals. 